Problem Reports
Mercury Mountaineer
Report: Plastic Intake Manifold May Crack Causing Coolant Leak
Mercury Mountaineer Problem
Model Years Affected: 1999, 2002, 2004, 2005
Electrical & Lights Affected: 4.6L V8
Average Mileage: 103,203 mi (47,000 mi - 146,000 mi)
The composite (plastic) intake manifold may crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. No recall was issued for this problem but Ford did extend the warranty to seven years on some models from the date of purchase.
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Report #1Visitor, 2004 Mercury Mountaineer, 47,000 mi
manifold was leaking - odor -signified the problem - item was replaced- cost -$1200.00
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Report #2
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Report #3Visitor, 2004 Mercury Mountaineer
The composite (plastic) intake manifold cracked near the thermostat housing and caused a coolant leak. The coolant runs down on the spark plugs causing the vehicle to run rough.
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Report #4Visitor, 2002 Mercury Mountaineer, 118,565 mi
cracked manifold thermostate housing. had to find a used housing while broke down in branson ms. used part and labor cost 500.00 only dealer in town wanted 1,500.00.
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Report #5Visitor, 2002 Mercury Mountaineer, 130,000 mi
cracked plastic housing caused coolant leak.
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Report #6Visitor, 2002 Mercury Mountaineer, 146,000 mi
cracked manifold thermostat housing. Tried to stop the leak with liquid weld--no good. As soon as the car heats up it breaks the welding.
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Report #7Visitor, 2002 Mercury Mountaineer, 122,000 mi
vehicle started leaking antifreeze about a week ago. Manifold now corroded. $700 repair bill
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Report #8karina, 2005 Mercury Mountaineer, 115,000 mi
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Report #9Visitor, 2004 Mercury Mountaineer, 101,000 mi
the suv ran hot but gauge in the dash did not show it. my dad open the hood the next day when i told him about having problems and he found the gasket to the thermastate was broke and when I had started the ride water came out all around the plastic intake manifold. he took it off it had came apart completely. I have order the part and my dad will put it on for me. I am hoping it did not cause no mager damage. but consider the low oil pressure light CAME ON I AM NOT TO HOPEFULL. WE ARE LOOKING FOR ANOTHER VECHILE KNOW.
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Report #10Visitor, 1999 Mercury Mountaineer, 76,220 mi
Driving down the road, pressed gas pedal and white smoke started coming out back. I pulled over and antifreeze was all over the inside of the engine and hood. Looked and intake manifold where thermostat is housed was completely cracked. It's been leaking for the past month causing antifreeze to cause the ignition coils in cylinder 7 and 8 to go bad. Now it's completely cracked. A shame ford never officially recalled this, poor design that is now costing consumers a hefty bill for a new intake manifold to replace something that wasn't manufactured right to begin with!
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Report #11Visitor, 2002 Mercury Mountaineer, 77,000 mi
minor water leak found. When further check was done it was found that it had a leak in the crossover below the thermostat housing where it bolts to the intake manifold. Matches the recall but past the 7 years so am looking at $1,000 to fix something that Ford/Mercury knew was a problem but did not tell us about.
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Report #12Visitor, 2002 Mercury Mountaineer, 141,000 mi
Had car diagnosed for not starting...ground wires were cleaned and the intake manifold was found to be damaged...replacement cost around $650!
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Report #13Visitor, 2004 Mercury Mountaineer, 100,058 mi
I just purchased this vehicle from a private seller. I saw that it was leaking coolant but got a good price on the mountaineer so purchased it anyway. I took it in to get inspected and had every problem listed on this forum. intake manifold was cracked could not find anywhere but dealer cost 700.00 with labor. It also needed rear bearings and hubs replaced and the back emblem has a crack around it. Total cost to repair all problems 1400.00. That bill should go directly to ford because this is a problem that seems to occur on many of the mountaineers.
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Report #14Visitor, 2004 Mercury Mountaineer, 92,000 mi
Big puddle of coolant under the truck and found that the leak was in two spots, intake manifold and water pump. Repairs cost 1200 +, but the warranty company will foot the bulk of the bill.
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Report #15Visitor, 2005 Mercury Mountaineer, 75,798 mi
Noticed car was leaking coolant, took it to the mechanic who diagnosed the cracked plastic intake manifold. Ordered a new part ($415.00) and fixed the problem.
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